Honeywell VE4000, VE5000 SERIES Operating instructions

Honeywell

VE4000 & VE5000 SERIES

CLASS "A" GAS VALVES

INSTRUCTION SHEET

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APPLICATION

These series class A gas valves are used for control and

regulation of gaseous fluids in gas power burners, atmospheric

gas boilers, melting furnaces, incinerators and other gas

consuming appliances

GENERAL

DESCRIPTION

VE4000 Series Gas Valve

The VE series gas valves offer a series of functionalities:

 Gas valves, Normally Closed.

 CPI switch optional

 Gas valves for use with Honeywell V4055, V4062 and

V9055 fluid power actuators.

 Relief valves Normally Open.

 Adjustable opening characteristics optional

FEATURES

 The VExxxxX1xxx series gas valves have a wrench boss

as well on inlet side as on outlet side for pipe fitting

incorporated in the valve housing.

 The VExxxxXXX3xxx and VE5xxxXXX3xxx series gas

valves are equipped at both sides with mounting holes to

adapt a pilot solenoid valve combination, to allow either

internal or external pilot gas. Furthermore these valves

are equipped with two M6 mounting holes to adapt an

A4020A electronic leak test The VExxxxBXX series gas

valves have an adjustable flow rate regulator on top of the

coil.

 For the VE series gas valves a series of field replaceable

connection boxes (including circuits) are available

 The VExxxxCXX series gas valves have adjustments for

step pressure flow rate and opening speed in hydraulic

damper unit on top of the coil.

 The VExxxxSXX series gas valves normally open relief

valves have no option for mounting a CPI switch

 The VE5xxxX3xxx series gas valves can be equipped with

a wide range of Honeywell fluid power actuators. These

fluid power actuators are field replaceable.

Honeywell

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MODEL CHART

Options 1000/2000 series internal thread 3000/4000 series flange connection

DN10 / 3/8” VExx10

DN15 / 1/2” VExx15

DN20 / 3/4” VExx20

DN25 / 1” VExx25

DN32 / 1 1/4” VExx32

DN40 / 1 1/2” VExx40

DN50 / 2” VExx50

DN65 / 2 1/2” VExx65 VExx65

DN80 / 3” VExx80 VExx80

DN100 / 4” VEx100

Non adjustable ON/OFF (VExxxxAXX) Standard Standard

Flow regulator (VExxxxBXX) Optional Optional 2)

Adjustable opening and flow regulator

(VExxxxCXX) Optional 1) Not available

Motorized opening: ON/OFF

(VE5xxxAxxxx) Not available VE5065A3xxx

VE5085A3xxx

VE5100A3xxx

Motorized opening: characterized

(VE5xxxCxxxx) Not available VE5065C3xxx

VE5085C3xxx

VE5100C3xxx

Safety relief valve, ON/OFF, Normally

Open, with or without position

indication switch (VExxxxSxxxx)

Optional for:

VE..20

VE..25

Not available

1) Except VExx65/VExx80

2) Except VE4100

TECHNICAL

SPECIFICATIONS

VE series solenoid gas valves

VExx10 (DN 10)

VExx15 (DN 15)

VExx20 (DN 20)

VExx25 (DN 25)

VExx32 (DN 32)

VExx40 (DN 40)

VExx50 (DN 50)

VExx65 (DN 65)

VExx80 (DN 80)

VEx100 (DN 100)

VE series suitable for fluid power actuators

VE5065 (DN 65)

VE5080 (DN 80)

VE5100 (DN 100)

Pipe sizes 1000/2000 series

Inlet and outlet G3/8" up to G21/2" internal parallel pipe thread according ISO 7-1

Pipe sizes 3000/4000 series

Flanged connection DN 65, DN 80 and DN100 according to DN 16 UNI 2223.

Torsion and bending stress

Pipe connections meet Group 2 according EN 161 requirements.

Honeywell

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Ambient temperature

-15 °C ... 60 °C

Supply voltage

24 V, 50/60 Hz 1)*

100-120 V, 50/60 Hz

200-240 V, 50/60 Hz

The applicable voltage is led to the solenoid coil via a rectified circuit.

1): only for DN10 up to DN50

Operational voltage range

The gas valve will function between 85% and 110% of the rated voltage

Electrical connection VE4xxx/VE6xxx/VE8xxx

Option 1: Wiring on terminal block on circuit cables entering box via M20 Cable Gland

Option 2: Connection by means of DIN plug on DIN faced connection located on front cover according to

ISO4400 / DIN EN 175301-803

Electrical connection VE5xxx series

See product literature fluid power actuators

Enclosure VE4xxx/VE6xxx/ VE8xxx

IP 65 when using supplied M20 gland and cable

diameter 7 – 13 mm for M20 version or using suitable DIN plug with gasket.

Capacity

See page 7 and 8

Maximum operating pressure

Inlet Maximum operating pressure

(mbar)

VE4010

VE6010

VE8010

200 or 360

360

200

VE4015

VE6015

VE8015

200 or 360

360

200

VE4020

VE6020

VE8020

200 or 360

360

200

VE4025

VE6025

VE8025

200 or 360

360

200

VE4032

VE6032

VE8032

200 or 360

360

200

VE4040

VE6040

VE8040

200 or 360

360

200

VE4050

VE6050

VE8050

200 or 360

360

200

VE4065/VE6065

VE8065

VE5065

200 or 360

200

VE4080/VE6080

VE8080

VE5080

200 or 360

200

500

VE4100

VE6100

VE5100

200 or 360

360

Honeywell

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POWER CONSUMPTION (VA)

Power consumption (VA) 200 mbar versions

V

ExxxxXXL

versions

Shut off valves

Model

number

24 V 50/60

Hz

Nominal

24 V 50/60 Hz

110% Nominal 200-240 V

50/60 Hz Nominal

200-240 V

50/60 Hz

110% Nominal

VExx10 15 16.5 11-16 12-17,5

VExx15 15 16.5 11-16 12-17,5

VExx20 21 23 17-24 19-26,5

VExx25 21 23 17-24 19-26,5

VExx32 50 55 31-44 34-48,5

VExx40 50 55 31-44 34-48,5

VExx50 49 54 35-51 38,5-53,5

VExx65 88 97 68-98 75-108

VExx80 88 97 68-98 75-108

VEx100 Start up - - 112-162 123-178

Cont. - - 28-40 31-44

Power consumption (VA) 360 mbar versions VExxxxXXH

versions

Shut off valves

Model

number

100-120 V

50/60 Hz

Nominal

100-120 V

50/60 Hz

110% Nominal

200-240 V

50/60 Hz Nominal 200-240 V

50/60 Hz

110% Nominal

VExx10 13-19 14-21 11-16 12-17,5

VExx15 13-19 14-21 11-16 12-17,5

VExx20 17-24 19-26,5 17-24 19-26,5

VExx25 17-24 19-26,5 17-24 19-26,5

VExx32 41-59 45-65 35-51 38,5-53,5

VExx40 41-59 45-65 35-51 38,5-53,5

VExx50 53-76 58-84 48-70 53-77

VExx65 Start up 205-295 225-325 191-274 210-301

Cont. 51-74 56-81 48-69 53-76

VExx80 Start up 205-295 225-325 191-274 210-301

Cont. 51-74 56-81 48-69 53-76

VEx100 Start up 180-259 198-285 456-657 501-723

Cont. 45-65 50-72 115-164 127-180

Honeywell

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Power consumption (VA) 360 mbar versions

V

ExxxxSGH

versions

Safety relief valves

Model

number

24 V 50/60

Hz

Nominal

24 V 50/60 Hz

110% Nominal

100-120 V

50/60 Hz

Nominal

100-120 V 50/60

Hz 110% Nominal 200-240 V

50/60 Hz

Nominal

200-240 V

50/60 Hz

110%

Nominal

VExx20S 16 19 14 17 16 19

PERFORMANCE CHARACTERISTICS

Opening time (except VE5xxx series)

VExxxxAXX &,BXXX versions: less than 1 second

VExxxxCXX version: adjustable from 1 up to 30 seconds at rated capacity

Closing time

VExxxxAXX, BXX, CXX and S series (except VE5xxx series)

Less than 1 second

Maximum working cycles/minute

S versions: 20

DN10–DN 25 AXX & BXX versions: 20

DN10-DN25 C versions: 1

DN32-DN100: 1

VE5... series: 1 cycle per 2 minutes

Duty cycle

Coil suitable for permanent energization

Honeywell

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INSTALLATION

WARNING

 Take care that installer is a trained experienced

service man.

 Turn off gas supply before starting installation.

 Disconnect power supply to prevent electrical shock

and/or equipment damage.

Mounting position

The gas valve can be mounted plus or minus 90 degrees from

the vertical.

Mounting location

The distance between the gas valve and the wall/ground, must

be at least 30 cm.

WARNING

 The outlet of a pressure relief valve (VE4000S series)

must always be connected to open atmosphere.

Main gas connection threaded valves

 Take care that dirt cannot enter the gas valve during

handling.

 Ensure the gas flows in the same direction as the arrow

on the housing of the gas valve.

 Use a sound taper fitting with thread according to ISO 7-1

(BS 21, DIN2999) or a piece of new, properly reamed

pipe, free from swarf

 Do not thread or tighten the pipe or pipe fitting too far.

Otherwise valve distortion and malfunction could result.

 Apply a moderate amount of good quality thread

compound to the pipe or fitting only, leaving the two end

threads bare. PTFE tape may be used as an alternative.

 In order to tighten the pipe in the valve, do not use the

actuator as a lever but use a suitable wrench operating on

the wrench bosses.

Main gas connection flanged valves

 Take care that dirt cannot enter the gas valve during

handling.

 Ensure the gas flows in the same direction as the arrow

on the housing of the gas valve.

 Ensure that inlet and outlet flanges are in line and

separated from each other enough to allow the valve to be

mounted between them without damaging the gasket.

 Place gasket. If necessary grease it slightly to keep it in

place.

 Mount gas valve between flanges using the bolts for each

flange.

WARNING

Tightness test after installation

 Paint all pipe connections and gaskets with a strong

soap and water solution..

 Start the appliance and check for bubbles. If a leak is

found in a pipe connection, remake the joint. A gasket

leak can usually be stopped by tightening the

mounting screws. Otherwise, replace the gas valve.

Electrical connection

CAUTION

 Switch off power supply before making electrical

connections.

 Take care that wiring is in accordance with local

regulations.

Use lead wire which can withstand 105 °C ambient.

The electric on/off operator is provided with a terminal block

for electrical connections.

Wiring

Follow the instructions supplied by the appliance

manufacturer.

Honeywell

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Instructions Electrical connections

Connection instructions with PG gland

On each side of the connection box there are break out

area’s. See Fig 1. After removing the central part of one of

these break outs, the PG gland (supplied with the valve) can

be fitted.

Fig 1

After removing the nut from the gland, the gland can be

placed in the break out. The nut needs to turned onto the

gland inside the box and tightened as shown in Fig 2.

Specified torque for the nut: 4 Nm. Mounted PG gland

shown in Fig 3. Specified torque PG gland: 3 Nm.

Fig 2

Fig 3

After connecting wires ( L, N & PE) to dedicated connectors

on connector block, the connection needs to closed by

mounting the front cover. Before placing the cover, please

check the correct position of seal as shown in Fig 4. The

cover can only be mounted in one orientation. This is shown

in Fig 5.

Specified torque for cover screw: 0.5 Nm.

Specified cable diameter for gland: 7 – 13 mm.

Fig 4

Fig 5

Connection instructions DIN plug

Specified torque for DIN connector screw: 0.2 Nm.

Fig 6

Honeywell

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ADJUSTMENT AND FINAL CHECKOUT

WARNING

 Adjustments must be made by qualified persons only

CAUTION

 To ensure a safe closing of the valves, it is essential

that voltage over the terminals of operators is

reduced to 0 Volt.

IMPORTANT

To ensure a satisfactory setting of the valve the

pressure drop over the valve should be at least 10%

of the supply pressure or 2.5 mbar which ever is the

greatest.

VExxxxB SERIES

(see fig 7.)

Flow rate adjustment

 Remove the cap screw from top of the coil.

 Place a socket head wrench into the adjustment nut.

 Turn wrench counter--clockwise to increase or clockwise

to decrease flow rate.

 Replace cap screw.

Flow adjustment fig 7

VExxxxC SERIES

(see fig. 8, 9 and 10)

The following characteristics can be adjusted:

 flow rate

 step pressure

 opening speed

Step pressure adjustment

 Remove the cap from top of the coil by loosening both

screws.

 Place a screw driver in the slot of adjustment screw which

is situated in center of the valve.

 Turn screw driver counter--clockwise to increase or

clockwise to decrease step pressure.

 Replace cap on top of the coil.

Step pressure adjustment. Fig 8

Opening speed adjustment

 Remove the cap from top of the coil by loosening both

screws.

 Place screw driver in the slot of adjustment screw which is

of center line.

 Turn screw driver counter--clockwise to increase the

opening speed and therefore the time till full opening will

decrease.

 Turn screw driver clockwise to decrease the opening

speed and therefore the time till full opening will increase.

 Replace cap on top of the coil.

Opening speed adjustment. Fig 9

)

Flow rate adjustment

 Remove the cap screw from top of the coil by loosening

both screws

 Place a wrench onto the adjustment nut.

 Turn wrench counter--clockwise to increase or clockwise

to decrease flow rate.

 Replace cap screw.

Flow rate adjustment. Fig 10

Final checkout of the installation

Set appliance in operation after any adjustment and observe

several complete cycles to ensure that all burner components

function correctly.

Honeywell

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STANDARDS AND APPROVALS

Honeywell

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REPLACEMENT PARTS AND ACCESSORIES

WARNING

Take care that only qualified persons carry out the installation of parts, accessories, and add on components.

Follow the installation instructions included in the package.

Check that the selected part, accessory or add on component is the correct one for the application in question.

Specification of data is given in the instruction leaflet in the package .Replace the old gaskets with the new ones

supplied in the package and check for leakage when the supply is switched on again. After installation and/or

replacement has been completed, a gas leak test must be carried out. Also check the gas valve for satisfactory operation

after fitting accessories.

SPARE CONNECTION BOXES

Valve type Voltage Connect. Ordering

number

VExx10/VExx15 24 M20 KTBBE00-115

100-120 M20 KTBBE00-115

200-240 M20 KTBBE00-115

VExx10/VExx15 24 DIN KTBBE00-215

100-120 DIN KTBBE00-215

200-240 DIN KTBBE00-215

VExx20/VExx25 24 M20 KTBBE00-120

100-120 M20 KTBBE00-120

200-240 M20 KTBBE00-120

VExx20/VExx25 24 DIN KTBBE00-220

100-120 DIN KTBBE00-220

200-240 DIN KTBBE00-220

VExx32XXL

/

VExx40XXL

24 M20 KTBBE00-141

100-120 M20 KTBBE00-140

200-240 M20 KTBBE00-140

VExx32XXH

/

VExx40XXH

24 M20 -

100-120 M20 KTBBE00-150

200-240 M20 KTBBE00-150

VExx32XXL

/

VExx40XXL

24 DIN KTBBE00-241

100-120 DIN KTBBE00-240

200-240 DIN KTBBE00-240

VExx32XXH

/

VExx40XXH

24 DIN -

100-120 DIN KTBBE00-250

200-240 DIN KTBBE00-250

Valve type Voltage Connect. Ordering

number

VExx50 24 M20 KTBBE00-150

100-120 M20 KTBBE00-150

200-240 M20 KTBBE00-150

VExx50 24 DIN KTBBE00-250

100-120 DIN KTBBE00-250

200-240 DIN KTBBE00-250

VExx65XXL

/

VExx80XXL

24 M20 KTBBE00-182

100-120 M20 KTBBE00-180

200-240 M20 KTBBE00-180

VExx65XXH

/

VExx80XXH

24 M20 -

100-120 M20 KTBBE00-181

200-240 M20 KTBBE00-181

VExx65XXL

/

VExx80XXL

24 DIN KTBBE00-280

100-120 DIN KTBBE00-280

200-240 DIN KTBBE00-280

VExx65XXH

/

VExx80XXH

24 DIN -

100-120 DIN KTBBE00-281

200-240 DIN KTBBE00-281

VEx100 100-120 M20 KTBBE00-100

200-240 M20 KTBBE00-100

VEx100 100-120 DIN KTBBE00-200

200-240 DIN KTBBE00-200

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Honeywell VE4000, VE5000 SERIES Operating instructions

Honeywell VE4000, VE5000 SERIES Operating instructions

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